APICS Detailed Scheduling and Planning

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Table of Contents
Instructor Guide
© 2016 APICS Confidential and Proprietary
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Session 1—Inventory Policies
Types and Classifications of Inventory ........................................................................... 1-9
Major Types of Manufacturing Inventory .................................................................................. 1-9
Subclassifications of Manufacturing Inventory.. ...................................................................... 1-15
Other Manufacturing Inventory.................................................................................................. 1-17
Service Inventory ....................................................................................................................... . 1-21
Aggregate Inventory Policies........................................................................................... 1-27
Resolving Sales and Operational Conflicts ............................................................................... 1-27
Inventory Valuation..................................................................................................................... 1-31
Inventory Performance Metrics ................................................................................................. 1-39
Item Inventory Policies ..................................................................................................... 1-45
Lot Sizing ..................................................................................................................................... 1-45
Safety Stock ................................................................................................................................ 1-67
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Session 2—Inventory Planning
Order Review Methods ..................................................................................................... 2-7
Independent Demand ................................................................................................................. 2-9
Dependent Demand .................................................................................................................. . 2-21
Aggregate and Disaggregate Planning .......................................................................... 2-27
Manufacturing Planning and Control ......................................................................................... 2-27
MRP II for Service........................................................................................................................ 2-29
Impact of Lean Production Concepts ............................................................................. 2-31
Tighter Coupling of Production Activities ................................................................................... 2-31
Lean Production Tools ................................................................................................................ 2-37
Accuracy, Storage, Handling, and Tracking ................................................................... 2-43
Inventory Accuracy ...................................................................................................................... 2-43
Storage and Location of Inventory Items .................................................................................. 2-59
Handling, Tracking, and Tracing of Inventory ............................................................................ 2-65
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Session 3—Information Used in the Material Planning Process
Information Used in Material Planning...........................................................................
3-7
Inventory Data ............................................................................................................................
The Master Production Schedule ..............................................................................................
Engineering Data ........................................................................................................................
3-7
3-19
3-29
Characteristics of the Material Planning Process.........................................................
3-33
Material Planning in Different Production Environments ........................................................
MRP Model .................................................................................................................................
Planning Process Parameters ...................................................................................................
Performance Characteristics .....................................................................................................
3-33
3-41
3-43
3-47
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Session 4—MRP Mechanics: The Basics
Introduction .......................................................................................................................
4-7
MRP Objectives and Functions ..................................................................................................
4-7
The MRP Grid ..............................................................................................................................
4-9
Bills of Material ...........................................................................................................................
4-9
MRP Calculation of Gross and Net Requirements.........................................................
4-13
Gross and Net Requirements and Planned Orders ..................................................................
4-13
Sources of Gross Requirements ................................................................................................
4-13
Summary of MRP Process Logic. ...............................................................................................
4-33
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Session 5—Using MRP Outputs and Managing Projects
Maintaining the Material Plan........................................................................................ 5-7
Maintain Order Priorities ...........................................................................................................
Pegging.......................................................................................................................................
What-If Analysis and Simulation ...............................................................................................
Revision of Planning Parameters .............................................................................................
Closing the Loop ........................................................................................................................
Integration of Lean with ERP/MRP...........................................................................................
5-7
5-13
5-21
5-23
5-33
5-37
Project Management ....................................................................................................... 5-39
What is a Project?......................................................................................................................
Project Phases ...........................................................................................................................
Conceptual (Initiation) Phase ...................................................................................................
Planning Phase ..........................................................................................................................
Project Plan Elements ...............................................................................................................
Execution (Implementation) Phase ..........................................................................................
Monitoring and Control Phase ..................................................................................................
Closure Phase ............................................................................................................................
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5-39
5-41
5-41
5-43
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Session 6—Detailed Capacity Planning
Influences on Detailed Capacity Planning .................................................................... 6-7
Detailed Capacity Planning ...................................................................................................... 6-7
Major Influences on Detailed Capacity Planning .................................................................... 6-7
Flexibility of Capacity and Scheduling. .................................................................................... 6-9
Planning Material or Capacity First. ......................................................................................... 6-11
Manufacturing Environment .................................................................................................... 6-13
Capacity-Related Terminology and Concepts .......................................................................... 6-19
Information Used in Detailed Capacity Planning.......................................................... 6-27
Capacity-Related Data .............................................................................................................. 6-27
Load-Related Data and Sources of Load ........................................................................... 6-49
Detailed Capacity Planning Techniques ........................................................................ 6-53
System Design Specifications .................................................................................................. 6-53
Simulation and Modeling Techniques ..................................................................................... 6-67
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Session 7—Detailed Capacity Management
Capacity Requirements Planning ................................................................................... 7-7
Capacity Management .............................................................................................................. 7-7
Classical Capacity Requirements Planning ............................................................................. 7-9
Capacity Management in Process Industries ............................................................... 7-39
Process Industries ..................................................................................................................... 7-39
Key Process Industry Characteristics ....................................................................................... 7-39
Process Flow Scheduling .......................................................................................................... 7-41
Other Capacity Management Approaches .................................................................... 7-51
Line Balancing in Repetitive Manufacturing ............................................................................ 7-51
Capacity Management in Service Industries ........................................................................... 7-55
Performance Measurements .......................................................................................... 7-59
Introduction................................................................................................................................ 7-59
Key Performance Measures ..................................................................................................... 7-59
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Session 8—Establishing Supplier Relationships
Factors Determining Supply Relationships ................................................................... 8-7
Mutual Business Value Principles............................................................................................
Make-or-Buy Decision ...............................................................................................................
Purchasing Strategy ..................................................................................................................
Strategic Sourcing .....................................................................................................................
Tactical Buying ..........................................................................................................................
Tactical Buying Versus Strategic Sourcing ..............................................................................
Financial Viability ......................................................................................................................
8-7
8-9
8-13
8-17
8-19
8-19
8-21
Collaborative Relationships ............................................................................................ 8-25
Strategic Alliances .................................................................................................................... 8-25
Supplier Partnerships ............................................................................................................... 8-29
Supply Alternatives and Techniques .............................................................................. 8-33
Sole, Single, or Multiple Sourcing ............................................................................................ 8-33
Supplier-Managed Inventories ................................................................................................. 8-39
Cross-Functional Teams ........................................................................................................... 8-41
Communication with Suppliers ...................................................................................... 8-43
Strategic Communication ......................................................................................................... 8-43
Operational Communication .................................................................................................... 8-45
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Session 9—Supplier Partnerships
Product and Process Development ................................................................................ 9-7
Time-to-Market........................................................................................................................... 9-9
Conventional Versus Concurrent Engineering ......................................................................... 9-11
Supplier Involvement................................................................................................................. 9-11
Purchasing ........................................................................................................................ 9-13
Purchasing Approaches ............................................................................................................ 9-13
Types of Contracts ..................................................................................................................... 9-15
Supply Chain Acceleration .............................................................................................. 9-19
Total Cost of Ownership. ........................................................................................................... 9-19
Training ...................................................................................................................................... 9-23
The Role of Engineering ............................................................................................................ 9-23
Supplier Relationship Management ......................................................................................... 9-25
Delivery Approaches .................................................................................................................. 9-27
Supplier Rating System ............................................................................................................. 9-31
Appendix
Progress Check Answer Sheet........................................................................................ A-1
Bibliography...................................................................................................................... A-2
Index
Index .................................................................................................................................. Index 1
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